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Engmeering Fraclure Mechanics Vol. 26, No. 6;pp. 869-882, 1987
0013-7944/87 $3.00 + .I0 Printed in Great Bntain. 0 1987 Perzqmm
Journals Ltd.
FATIGUE THRESHOLD DETERMINATION IN HIGH STRENGTH COLD DRAWN
EUTECTOID STEEL WIRES
J. LLORCA and V. SANCHEZ-GALVEZ Department of Materials Science,
Universidad Polittcnica de Madrid, Ciudad Universitaria,
Madrid 28040, Spain
Abstract-The effect of stress ratio on fatigue threshold in cold
drawn eutectoid steel wires has been experimentally measured. Crack
growth rate measurements in the threshold region have been
accurately determined using SEM. These results are compared with
others from literature showing that fatigue threshold decreases
when yield strength increases in pearlitic steels.
1. INTRODUCTION
THE EXCEPTIONAL mechanical properties of the cold drawn
eutectoid pearlitic steels have permitted its utilization in big
civil engineering structures, such as long span prestressed
concrete bridges or nuclear power plants. In many cases, the most
severe conditions of design loading are cyclic, and this fact has
given impulse to study of the fatigue behaviour and particularly
the fatigue limit of these steels.
Among the studies performed to determine the fatigue limit of
these materials, the work done by FernLndez and others[2,7] must be
pointed out. This study, involving a high level of experimental
work, shows that the classical design method based upon Wiihler
curves is not directly applicable without the support of
statistical models due to the high scatter of the empirical results
(Fig. 1). The reason for such a high scatter must be found in the
surface state of these steels and fracture mechanics is the only
way to achieve results used in engineering design.
On the other hand these steels show low fatigue properties as
compared with their mechanical properties under monotonic loading,
like the high strength martensitic steels. Usually, the fatigue
limit 0, for a stress ratio R = 0 is similar to the cyclic yield
stress o&3]. For mild steels o,,~= 0.65 or and thus +/o,zO.65.
This condition is equivalent to the assumption that plastic strains
must develop in a smooth surface to initiate a crack.
Previously[4], the authors have obtained
390
-!- f... ..._... t 380
-C
5 370 1
. . . ._m . . . . . . .
. . ..__.. . . . . .
. ..a__.. _ . .
. FAILURE O-RUN OUT
4 360
t
. .... . . . . . S... . . . . . . . . . ... . . . . .
350- . . . . . . . . . . . . . . .
% . . . . . . . . . -.._ . .
5 340- . . . .- . .._ . . . . . . . .
L2: . . . . . . . . . . . . . . . . .
330- . . . . . . . . . . . . . f . . . . .
?I . . . . . . . . . . . . . . . . . . . .
k! 320- . . . . . .._.. . . . . ._.. . . .
z . . . . . I. . . . . _ . . . . . . .
310- . . . . . . . . . . . . . . . . . . . .
. .*. . . . . . . . . . . .
3OG- . . . . . . . . 1
. . . . . 1
290- . . 2 .
2.30 2
1 I 1 1 1 2
5.104 105 2.105 5.105 106 2.106 5.106
20-
NUMBER OF TESTS
20
20
20
20
20
20
20
20
20
20
20
20
20
24
- 24
- 24
- 24
- 24
- 24
- 24
- 24
- 24
CYCLES Fig. 1. Experimental evidence of the large scatter in
fatigue life of eutectoid cold drawn wires (from
reference [Z]).
-
870 J. LLORCA and V. SANCHEZ-GALVEZ
experimentally the cyclic yield stress in cold drawn eutectoid
steel wires. Tests were performed on smooth specimens under strain
control and strain ratios R,= E,in/Emax >O. When &,,, 0.55%
cyclic softening was observed, which increases with smax and As.
For instance, for &iX = A&, the oYc is equal to 0.92
oY.
In accordance with that, a high fatigue limit for these steels
could be expected. However, it is well known that those high values
are never achieved. Since fifty years ago, Pomp and Duckwitz[5]
found that the fatigue limit of cold drawn steels decreased with
the increase of reduction of area during the drawing process and it
was in between 40% of the ultimate tensile strength for a reduction
of area of 44% and 25% of the u.t.s. for a reduction of 90%.
Castillo[2] performed 72 tests with specimen lengths ranging
from 140 to 8540 mm. His results show a fatigue limit between 0.2
and 0.3 oY depending on the specimen length. Birkenmaier and
Narayanan[6] performed more than 200 tests and found a relation
or/c+ = 0.23 for specimens of 200 mm of length. Similar values were
found by Verpoest and others[7] testing 2 mm diameter wires and
different values of the yield stress (see Table 1).
Such wide experimental results clearly indicate that high stress
concentrations must exist on the surface of these steels, leading
to low cyclic stresses to initiate a crack. These stress
concentrations might be produced either by imperfections of the
steel surface or by the interface between matrix and inclusions,
which could possess different mechanical properties. Fowler[8] has
shown the detrimental effect on the fatigue limit of the increase
in the content of inclusions in eutectoid pearlitic steels. If the
main cause of the low fatigue limit of cold drawn eutecoid steels
were the inclusions, no differences would be observed when the
steel surface was polished to eliminate surface imperfections.
PO-we Kao and Byrne[27] carried out such work, but they found that
a higher resistance to fatigue crack initiation is obtained when
the specimen surface was polished in cold drawn steels. On the
other hand, several authors[7,9] reported that crack propagation
begins at the tip of a surface flaw (Fig. 2).
The surface state of these steels has been deeply examined by
Cetial[lO]. Flaws found were inclusions, cavities and cracks
associated to the cavities. The mean width of the inclusions
(perpendicular to the wire axis) was measured. In the majority of
the samples studied, cavities deeper than 50 pm were found, and
associated to these cavities, cracks with lengths up to 40 urn were
also found.
Verpoest and collaborators[7] assumed that, for these steels,
cracks propagate from the very beginning from surface flaws,
without any crack initiation time. According to the experimental
results outlined above, this assumption can be checked: No fatigue
crack initiation exists because cracks are always present on the
steel surface. Therefore, no fatigue failure will happen provided
that the stress intensity factor range AK is below the threshold
value AKth. It follows the importance of the determination of the
threshold stress intensity factor range AKth to characterize the
fatigue behaviour of cold drawn eutectoid steels.
It is well known the large influence of the stress ratio R on
the threshold stress intensity factor range AKth[l 11. This
influence has a prime importance for a safe design with these
steels, and it has been the main objective of this research.
Table 1. Experimental values of fatigue limit (oj) and yield
strength (o,) for eutectoid cold drawn wires
Reference Number of Tests
Specimen length (mm)
(M%a)
32 140 1500 415 0.27 26 1960 1500 315 0.21 14 8540 1500 294
0.20
210 200 1548 360 0.23 35 1111 390 0.35 68 1207 366 0.30 38 1578
421 0.27 36 1902 471 0.25 35 1952 565 0.29
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Threshold determination in eutectoid steel wires 871
Fig.
Fig. 2. Surface defect from which fatigue crack began to
propagate (x 400).
Fig. 3. Fatigue crack coloured by heat treatment.
4. SEM Micrograph showing differences between crack propagation
near threshold (left) and posterior fracture (right) ( x 550).
-
872 J. LLORCA and V. SANCHEZ-GALVEZ
Fig. 10. Fatigue crack SEM with AK=20 MPa no;* showing a ductile
fracture mechanism (x 2040).
Fig. 11. Fatigue crack SEM with AK=5 MPa # ( x 2040).
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Threshold determination in eutectoid steel wires 873
2. EXPERIMENTS
Material The chemical composition and the mechanical properties
of the steel are summarized in Table
2. The processing of the steel included the production of 12 mm
diameter wires by rolling. These wires were austenized at 1200C and
patented in a lead bath at 850C and finally cooled in air; after
which the wires were cold drawn in several passes until 7 mm
diameter wires were achieved. The final product was stress-relieved
by heating at about 450C for a few seconds. The microstructure is a
fine pearlite with an interlaminar distance in the pearlite below
0.25 p.
Crack growth rate determination Due to the small diameter of the
steel wires and its circular shape, the usual techniques used
to determine the crack growth rate are difficult to apply for
obtaining the threshold stress intensity factor range, that
involves a high accuracy in the measurements[12].
The travelling microscope yields very accurate measurements of
the crack growth in the surface, but for the geometry under study,
there is a state of plane stress in the surface, while in the
inside of the specimen there is a state of plane strain. Numerical
calculations provide accurate values of the stress intensity factor
along the crack front inside the specimen, but fail to give a
definite value in the surface, since there the degree of the
singularity depends on the angle between the crack front and the
surface of the specimen[13]. Therefore, although accurate values of
the crack growth rate might be obtained, it would not be possible
to derive a correlation with accurate values of the stress
intensity factor range.
The technique based upon the measurement of the compliance of
the specimen yields good results at high crack growth rates (above
10m9 m/cycle) but it is not appropriate for lower rates due to the
high scatter of the results at the low values of the load necessary
for obtaining the AL
Other systems more sophisticated (acoustic emission, holography
or high frequency alternating currents) permit the detection of
small cracks. For instance, with the use of alternating currents of
40 kHz of frequency, cracks with an area of about 0.05% of the
total area of the wire can be detected. But the system fails to
give accurate information about the depth of the crack, not
uniquely related to the area of the crack. On the other hand, the
electric noise introduces a scatter not negligible as compared with
the low voltage drops measured[12]. Summarizing, although these
techniques have permitted important advances in the detection and
study of microcracks, its utilization for the obtention of the
threshold stress intensity factor range for crack growth involves a
high scatter of the results.
The method followed for the measurement of the crack depth
increment Aa had the aim of achieving a high accuracy. With that
aim, after fatigue precracking, the specimen was lightly heat
tinted. In tests at R = 0.5 and R 2 0.8, the specimen was heated at
200C for about 15 minutes while in tests at R = 0.1 the heating
time was reduced to 10 minutes. In this way, the oxide film was
thinner and its possible influence on the threshold stress
intensity factor range by crack closure was lessened. After
testing, the specimens were fully broken in tension in air and the
crack depth increment Aa was measured by means of a profile
projector and a scanning electron microscope. The area of crack
growth was easily distinguishable from the precrack by its
different colour and from the final ductile fracture by its
different texture (Figs 3 and 4). With this system an accuracy of f
3 pm in the measurement of Aa was achieved.
Experimental method Tests were performed on 7 mm diameter wires
in an Instron dynamic testing machine under
load control and sinusoidal wave. The frequency was different
from one test to another, but always below 20 Hz, since it is known
that it has no influence on the crack growth[14]. Both in the
Paris
Table 2. Chemical composition (X) and mechanical properties of
steel tested
C Mn Si P S N (&a)
q.0. I %
Q2 WI (M>a) (2) (g
0.82 0.60 0.18 0.010 0.024 0.007 197.000 1340 1370 1720 5.06
29.6
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874 J. LLORCA and V. SANCHEZ-GALVEZ
range (da/dN > lo- m/cycle) as well as in the range near the
threshold the crack growth rates were determined.
In the Paris range, specimens were previously notched by means
of a file, the notch depth being about 1 mm, and then fatigued at a
constant load amplitude. The crack growth rate was obtained by
measuring the stiffness change by means of a dynamic extensometer
of 12.5 mm gauge length attached to the lips of the notch. A
previous calibration curve of crack depth vs specimen stiffness
gives the actual crack depth during the test.
In the tests performed to determine the threshold stress
intensity factor range, a notch of straight front and 1.0 or 1.2mm
of depth was previously produced by electro-erosion. It was checked
that with this technique the loads needed to initiate a crack were
lower than with notches produced by machining, probably because the
former way induces lower compressive stresses in the notch tip than
the machining way. With this method, the number of load blocks of
decreasing amplitude required to arrive at the threshold is lower,
easing the procedure.
In order to obtain reliable values of AKth, the crack closure
effect had to be taken into account. To avoid that problem,
cracking was produced following different systems for different
values of R. For values of R 2 0.8, the maximum stress was held
constant, and the minimum stress was progressively increased until
AK was small enough (Fig. 5a). For R = 0.5, cracking was produced
at R = 0 and then, the maximum stress was progressively reduced
(Fig. 5b). For R =O.l, cracking was also produced at R = 0 and the
maximum stress reduced for each stress block. In the last two
blocks before reaching a AK value close to the threshold the
maximum stress was reduced by only lo%, according to the usual
techniques for this kind of test (Fig. 5~). During precracking,
crack growth was tracked by means of a dynamic extensometer. In all
tests, the crack propagated at least 200pm in the last loading
block. This length is much greater than the plastic zone size that
could be produced by any hazardous overload during the last loading
blocks.
K T Rz0.5
R = 0.1
Fig. 5. Fatigue precracking scheme for (a) R > 0.8 tests, (b)
R = 0.5 tests, (c) R = 0.1 tests
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Threshold determination in eutectoid steel wires 875
Table 3. Paris law parameters for different stress ratios
R c m (m/c x lo-) (Go)
0.8 4.633 1.993 96 0.5 2.052 2.293 98 0.1 1.107 2.417 98.3
After precracking, the specimen was heat tinted in the way
described before and was subjected to the desired cycling loading.
Finally, the specimen was broken under monotonic loading and the
crack growth Aa in the center of the crack was measured.
From the values Ao and a, the stress intensity factor range AK
was determined by the expression[ 141
AK = MAafia (1)
valid for a/D values greater than 0.15, the parameter M
being
M = (0.473 - 3.286(a/D) + 14.797(a/D)2)2((a/D) - (a/D)2)-4
(2)
where D is the diameter of the wire.
3. RESULTS AND DISCUSSION
The experimental results obtained for the 3 values of R used,
are shown in Fig. 6. As can be seen in all cases, a change of slope
in the curve da/dN vs AK can be observed for da/dN about 10m9
m/cycle. For greater values, the material follows the Paris law and
the values of the parameters A and m are shown in Table 3.
The three straight lines best fitting the results are drawn in
Fig. 7. As can be seen, higher R values yield crack growth rates
slightly greater for small AK values. This fact, reported
previously by other authors[15] can be explained taking into
account that the influence of crack closure increases when AK
decreases. When AK increases, the three straight lines are nearly
convergent. Anyhow, the difference is small and the scatter of the
results does not permit us to get more information.
Figure 8a illustrates the results for the range near the
threshold. Figures 8b and 8c show the scatter intervals of the
experimental results of crack growth rates and stress intensity
factor ranges taking into account the accuracy of measurements of
Aa and loads.
These results have been used in the determination of AKth for
the three R values following the criteria recently exposed by
Taylor[16] in a review. He points out, after having analyzed more
than seventy papers with experimental values of AKth, that some
criteria need to be adopted to guarantee that a value is reliable.
If the testing procedure is not appropriate, the threshold value
may be overestimated by the existence of overloads or even
underestimated if the cracks are small. The two main criteria
proposed by Taylor are: first, that the da/dN vs AK curve must
include at least one value below lo-lo m/cycle. When this condition
is fulfilled and no clear asymptote parallel to the da/dN axis
exists, the threshold stress intensity factor range AKth is the
value corresponding to a crack growth rate of lo- m/cycle.
According with these conditions, AK, values have been determined
and they are summarized in Table 4.
Table 4. AKth for different stress ratios
R da/dN (m/c x 10.*I)
da/dN scatter (m/c x 10.~)
A& scatter
0.8 1.06 0.74-1.37 2.8 2.3-3.3 0.5 1.28 1.161.40 3.8 3.54.2 0.1
1.10 l.OG1.22 5.2 5.0-5.4
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876 J. LLORCA and V. SANCHEZ-GALVEZ
(a) lC6jC
2 ttT7 - i P :: xi3 -
tog-
(b)
0
0
R 2 0.8 da/dN = C iAKlm
C : 4.633 .lO-
m = 1.993
R 3 0.5
daidN : C (AK)
C = 2.052.16
m : 2.293
R.= 0.1
da/dN = C (AK)m
c = 1.107.,0 16 - 0 m : 2.417
r = 93.4%
-12 10 L I 8 I L ,
1 2 5 10 20 50 100
AK .(MPa.m2)
AK ,(MPa rn?
AK 1 (MPa m)
Fig. 6. (a) Crack growth rate vs AK for R 3 0.8, (b) for R =
0.5, (c) for R = 0.1.
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Threshold determination in eutectoid steel wires 877
- R zO.8
/ ---- R ~0.5
-..- .._ R ~0.1
15 25 50 100
AK (MPa.rn2) ,
200
Fig. 7. Comparison between region II crack growth rates for
different R values.
The influence of R on the crack growth rate is greater near the
threshold. The experimental results show that, for the steel
tested, the crack propagation rate at AK=5 MPa ml/* is two orders
of magnitude greater for R = 0.8 than for R = 0.1. Although
qualitatively this phenomenon has been widely explained[ll], the
efforts to give a quantitative explanation from a theoretical model
have not been successful, due to the large influence of
microstructural factors.
Actually, these factors may produce an increment of crack
closure by increasing the roughness of the crack surface, or
provide different preferential orientations for the advance of the
crack front leading to crack branching. The influence of these
microstructural factors is thus very important and not easily
quantified. In pearlitic steels, the two main characteristics are
the austenitic grain size and the interlamellar spacing of the
pearlite[19]. Large austenitic grain sizes as well as high pearlite
interlamellar distance produce rougher crack surfaces, increasing
the crack closure effect and diminishing the effective force
available to produce the crack propagation.
Among the empirical expressions proposed[17], [18], the simplest
one that gives a good fit to experimental results has been the
linear relationship[20], [21]:
AKlh = AKtho - AR. (3)
Figure 9 shows the best fit to the experimental results by a
straight line for the three R values used, and a good agreement can
be observed.
The value of the parameter A has to be a function of the
mechanical properties and the microstructure of the steel. Since
for pearlitic steels the yield stress is a function of the
pearlitic interlamellar spacing, it can be assumed that the A value
will decrease for stronger steels giving rise to a weaker influence
of R on the threshold value. Table 5 includes a compilation of the
existent bibliography for ferritic-pearlitic steels with a
pearlitic content above 80%. With the exception of the results of
Mausonave and Bailon, all the results are in agreement with this
dependence of R with the yield stress.
Finally, another result can be discussed. Crack growth rates one
order of magnitude lower than the interatomic distance (about
2.1O-O m) have been measured. This fact means that the actual crack
propagation is discontinuous along the crack front, whilst for
da/dN greater than about lo- m/cycle, the propagation curve follows
the Paris law and the crack growth is continuous. At high growth
rates the fracture topography is the typical one for fatigue of
pearlitic steels (TTS)[28]. At low growth rates (below about 10m9
m/cycle) the fracture mechanism is different showing a faceted
crack path [19] (see Figs 10 and 11).
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878 J. LLORCA and V. SANCHEZ-GALVEZ
(a) lo76
A l
A l
0 l
A
l
I-do
! .A
O l e
0
16 0 a A
0 RZ0.8 l R:0.5 A R-0.1
Id2 1
I I I I
1 2 5 10 20
z_ m 1@- z S! 8
c( WI
,-dJ- c( Y
nn
;bO- k +ii
w
16 - -- w
-
Iti I I I I 1 2 5 10 20
(4 167
#II 1 2 5 10 20
AK ,(MPo.m*)
AK, (MPa .rn*)
AK, (MPa.m"*)
Fig. 8. (a) Experimental results of crack growth rates in the
near threshold region. (b) AK Experimental confidence limits. (c)
da/dN Experimental confidence limits.
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Threshold determination in eutectoid steel wires 879
6- AKth=5.54-3.43R
1 I I I I 0.0 0.2 0.4 0.6 0.6
R
1.0
Fig. 9. AK,, experimental dependence with R.
4. THE INFLUENCE OF oY AND R ON AKTH
As it was outlined above, the AK,, depends on the mechanical and
microstructural properties of the steel. In pearlitic steels, there
exists a simple relationship between them, because the higher the
yield stress, the lower the pearlite interlamellar distance.
Therefore, it seems possible to estimate AKth from cry, and this
possibility would be very interesting since the yield stress
determination is quite simple. The results previously published
have found such a relationship for martensitic steels[16], [20] but
not for pearlitic steels. The reason for this failure could be the
lack of data for high yield stresses, the necessity of comparing
results for the same R value and the scatter of the empirical
results. To avoid this last problem and achieve reliable data, the
criteria outlined by Taylor[16] have been followed.
Figures 12 to 14 illustrate the AKth values as a function of aY
with our data as well as data of the literature, for R = 0, R =
0.1, and R 2 0.6, and steels with pearlitic content above 80%.
Despite a high scatter, there is a clear trend to decrease AKth
when cry increases. These figures also show some phenomena that can
be discussed.
First of all, the influence of cr,, on AK,, is less important
for higher R values (see Fig. 14, for R 2 0.6) despite the few
available results. The explanation might be as follows: The two
main effects promoting the crack closure are the plasticity induced
near the crack tip and the surface roughness; since for high R
values the crack is always open and the CTOD values are greater
than the crack rugosities, the only effect on the crack closure is
the plasticity induced and thus the influence of R is much
smaller.
On the other hand, for aY > 1200 MPa, a lower influence of R
on AK,, is observed than for lower or values. This effect may be
understood taking into account that high yield stresses give
Table 5. Influence of yield strength on A parameter
Reference Steel my (MPa) A
1211 WI WI ~231 Cl81 Cl81 Cl81
This Paper
ANC 480-540 5.64 ACN 47&507 6.76
P 434 7.24 M 337 11.84 6-2 477 11.44 6T 477 12.99
532 11.28 NE& 1370 3.43
-
880 J. LLORCA and V. SANCHEZ-GALVEZ
DATA FROM REFERENCES :
[7] .[8]. [211 8 [4 0 [4 8 [26]
6-
I I I 1
0 400 800 1200 1600 260
Oy ,(MPa)
Fig. 12. AKth experimental values for pearlitic steels with R =
0.
rise to smaller plastic zones and to microstructures in which
the roughness is lower. If the crack closure effect is lower, so
will be the influence of R.
Finally, the straight line of Fig. 13 (R = 0.1) shows a higher
slope than the line of Fig. 12 (R = 0), which is opposite that
expected. Although the scatter of results for R = 0.1 is so high
that no definitive conclusions can be derived, this anomalous
behaviour may be attributed to the decrease of surface roughness in
the tests at R = 0 by fretting and erosion between the two lips of
the crack when it is fully closed in each cycle. The particles
pulled out by this friction may fill up the valleys of the crack
surface and the final result may be a smooth surface leading to a
lower influence of the crack closure induced by the roughness (Fig.
15). This effect must be taken into account when A&, values
were extrapolated from results obtained at different R values.
because the AKtho value determined may be overestimated.
ru- >E
d
2. .c
=1
lo-
6-
DATA FROM REFERENCES:
0 400 800 1200 1600 2&o
Oy , (MPa
Fig. 13. AK,, experimental values for pearlitic steels with R =
0.1.
-
Threshold determination in eutectoid steel wires 881
(1)
(2)
(3)
DATA FROM REFERENCES : [IS], [19] , [21] , 1221 , and this
paper
6- R ~0.6
U,, , Wa)
Fig. 14. AK,,, experimental values for pearlitic steels with R 3
0.6.
5. CONCLUSIONS
For the first time, reliable values of AKth as a function of R
have been determined for eutectoid cold drawn steels. Due to the
existence of surface flaws and cracks in actual steel wires, the
values obtained are of prime importance for fatigue design. The
experimental method used for obtaining AKth values, although it is
quite tiresome, has permitted the achievement of a high accuracy of
the results. It has been checked that pearlitic steels also show a
decrease of AKth when oY increases, if the results of the
literature are rationalized as a function of R.
Acknowledgements-The authors are indebted to Comision Asesora de
Investigacibn Cientifica y Tkcnica by the financial support for
this research through grant number 1459/82.
Fig. 15. Scheme of roughness induced closure diminution when R =
0.
-
882 J. LLORCA and V. SANCHEZ-GALVEZ
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(Received 4 Augusf 1986)